Magnetic powder and isotropic bonded magnet

ABSTRACT

Disclosed herein is a magnetic powder which can provide a magnet having a high magnetic flux density and excellent magnetizability and reliability especially excellent heat resisting property (heat stability). The magnetic powder is composed of an alloy composition represented by R x (Fe 1−y Co y ) 100-x-z-w B z Al w  (where R is at least one kind of rare-earth element, x is 8.1-9.4 at %, y is 0-0.30, z is 4.6-6.8 at %, and w is 0.02-1.5 at %), the magnetic powder being constituted from a composite structure having a soft magnetic phase and a hard magnetic phase, wherein the magnetic powder has characteristics in which, when the magnetic powder is formed into an isotropic bonded magnet by mixing with a binding resin and then molding it, the irreversible susceptibility (X irr ) which is measured by using an intersectioning point of a demagnetization curve in the J-H diagram representing the magnetic characteristics at the room temperature and a straight line which passes the origin in the J-H diagram and has a gradient (J/H) of −3.8×10− 6 H/m as a starting point is less than 5.0×10− 7 H/m, and the intrinsic coercive force (H CJ ) of the magnet at the room temperature is in the range of 406-717 kA/m.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to magnetic powder and an isotropic bondedmagnet produced using the magnetic powder.

2. Description of the Prior Art

For reduction in size of motors, it is desirable that a magnet has ahigh magnetic flux density (with the actual permeance) when it is usedin the motor. Factors for determining the magnetic flux density of abonded magnet include magnetic performance (that is, magnetization) ofthe magnetic powder and the content (that is, compositional ratio) ofthe magnetic powder contained in the bonded magnet. Accordingly, whenthe magnetic performance (magnetization) of the magnetic powder itselfis not sufficiently high, a desired magnetic flux density cannot beobtained unless the content of the magnetic powder in the bonded magnetis raised to an extremely high level.

At present, most of practically used high performance rare-earth bondedmagnets use the isotropic bonded magnets which are made using MQP-Bpowder manufactured by MQI Corp. as the rare-earth magnetic powderthereof. The isotropic bonded magnets are superior to the anisotropicbonded magnets in the following respect; namely, in the manufacture ofthe bonded magnet, the manufacturing process can be simplified becauseno magnetic field orientation is required, and as a result, the rise inthe manufacturing cost can be restrained. On the other hand, however,the conventional isotropic bonded magnets represented by thosemanufactured using MQP-B powder have the following disadvantages.

(1) The conventional isotropic bonded magnets do not have sufficientlyhigh magnetic flux density. Because of the low magnetic performance(that is, the insufficient magnetization) of the magnetic powder used,the content of the magnetic powder to be contained in the bonded magnethas to be increased. However, the increase in the content of themagnetic powder leads to the deterioration in the moldability of thebonded magnet, so there is a certain limit in this attempt. Moreover,even if the content of the magnetic powder is somehow managed to beincreased by changing the molding conditions or the like, there stillexists a limit to the obtainable magnetic flux density. For thesereasons, it is not possible to reduce the size of the motor by using theconventional isotropic bonded magnets.

(2) Since the conventional bonded magnet has high coercivity (coerciveforce), magnetizability thereof is poor, thus requiring a relativelyhigh magnetic field for magnetization.

(3) Although there are reports concerning nanocomposite magnets havinghigh remanent magnetic flux densities, their coercive forces, on thecontrary, are so small that the magnetic flux densities (for thepermeance in the actual use) obtainable for the practical motors arevery low. Further, these magnets have poor heat stability due to theirsmall coercive forces.

(4) The conventional bonded magnets have low corrosion resistanceproperty and heat resisting property. Namely, in these magnets, it isnecessary to increase the content of the magnetic powder to be containedin the bonded magnet in order to compensate the low magnetic performanceof the magnetic powder. This means that the density of the bonded magnetbecomes extremely high. As a result, the corrosion resistance and heatresisting property of the bonded magnet are deteriorated, thus leadingto low reliability.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide magneticpowder that can produce a magnet having a high magnetic flux density andhaving excellent magnetizability and reliability especially temperaturecharacteristics (that is, heat resisting property and heat stability),and provide an isotropic bonded magnet formed from the magnetic powder.

In order to achieve the above object, the present invention is directedto magnetic powder composed of an alloy composition represented byR_(x)(Fe_(1−y)Co_(y))_(100-x-z-w)B_(z)Al_(w) (where R is at least onekind of rare-earth element, x is 8.1-9.4 at %, y is 0-0.30, z is 4.6-6.8at %, and w is 0.02-1.5 at %), the magnetic powder being constitutedfrom a composite structure having a soft magnetic phase and a hardmagnetic phase, wherein the magnetic powder has characteristics inwhich, when the magnetic powder is formed into an isotropic bondedmagnet by mixing with a binding resin and then molding it, theirreversible susceptibility (X_(irr)) which is measured by using anintersectioning point of a demagnetization curve in the J-H diagramrepresenting the magnetic characteristics at the room temperature and astraight line which passes the origin in the J-H diagram and has agradient (J/H) of −3.8-10−⁶ H/m as a starting point is less than5.0×10−⁷ H/m, and the intrinsic coercive force (H_(CJ)) of the magnet atthe room temperature is in the range of 406-717 kA/m.

As described above, according to the present invention, the followingeffects can be obtained.

Since each of the magnetic powders has the composite structure having asoft magnetic phase and a hard magnetic phase and contains apredetermined amount of Al, they have high magnetizability and exhibitexcellent magnetic characteristics so that intrinsic coercive force andrectangularity thereof are especially improved.

The absolute value of the irreversible flux loss is small and excellentheat resisting property (heat stability) can be obtained.

Because of the high magnetic flux density that can be secured by thisinvention, it is possible to obtain a bonded magnet with high magneticperformance even if it is isotropic. In particular, since magneticperformance equivalent to or better than the conventional isotropicbonded magnet can be obtained with a magnet of smaller volume ascompared with the conventional isotropic bonded magnet, it is possibleto provide a high performance motor of a smaller size.

Moreover, since a higher magnetic flux density can be secured, inmanufacturing a bonded magnet sufficiently high magnetic performance isobtainable without pursuing any means for elevating the density of thebonded magnet. As a result, the dimensional accuracy, mechanicalstrength, corrosion resistance, heat resisting property (heat stability)and the like can further improved in addition to the improvement in themoldability, so that it is possible to readily manufacture a bondedmagnet having high reliability. In particular, when Si is containedtherein, further improved corrosion resistance can be obtained.

Since the magnetizability of the magnet according to this invention isexcellent, it is possible to magnetize a magnet with a lower magnetizingfield. In particular, multipolar magnetization or the like can beaccomplished easily and surely, and further a high magnetic flux densitycan be obtained.

Since a high density is not required to the bonded magnet, the presentinvention is adapted to the manufacturing method such as the extrusionmolding method or the injection molding method by which molding at highdensity is difficult as compared with the compression molding method,and the effects described in the above can also be realized in thebonded magnet manufactured by these molding methods. Accordingly,various molding method can be selectively used and thereby the degree ofselection of shapes for the bonded magnet can be expanded.

In this connection, it is preferred that the composite structure is ananocomposite structure.

Further, in the present invention, it is preferred that said R comprisesrare-earth elements mainly containing Nd and/or Pr. In this case, said Rincludes Pr and its ratio with respect to the total mass of said R is5-75%. When the ratio lies in this range, it is possible to improve thecoercivity and the rectangularity by hardly causing a drop in theremanent magnetic flux density.

Furthermore, in the present invention, it is also preferred that said Rincludes Dy and its ratio with respect to the total mass of said R isequal to or less than 14%. When the ratio lies in this range, thecoercivity can be improved without causing marked drop in the remanentmagnetic flux density, and an improvement of the heat resisting propertyis also possible.

Moreover, it is preferred that the magnetic powder is obtained byquenching the alloy of a molten state.

It is also preferred that the magnetic powder is obtained by pulverizinga quenched ribbon of the alloy which is manufactured by using a coolingroll.

Further, it is also preferred that the magnetic powder is subjected to aheat treatment for at least once during the manufacturing process orafter its manufacture.

Furthermore, it is preferred that the average grain size of the magneticpowder lies in the range of 0.5-150 μm.

The present invention is also directed to an isotropic rare-earth bondedmagnet, which is formed by binding the magnetic powder as set forth inthe above with a binding resin.

The present invention is also directed to an isotropic rare-earth bondedmagnet formed by binding magnetic powder containing Al with a bindingresin, wherein the isotropic rare-earth bonded magnet is characterizedin that the irreversible susceptibility (X_(irr)) which is measured byusing an intersectioning point of a demagnetization curve in the J-Hdiagram representing the magnetic characteristics at the roomtemperature and a straight line which passes the origin in the J-Hdiagram and has a gradient (J/H) of −3.8×10−⁶ H/m as a starting point isless than 5.0×10−⁷ H/m, and the intrinsic coercive force (H_(CJ)) of themagnet at the room temperature is in the range of 406-717 kA/m.

In the present invention, it is preferred that said magnetic powder isformed of R-TM-B-Al based alloy (where R is at least one rear-earthelement and TM is a transit metal containing Iron as a major componentthereof.

Further, it is also preferred that the magnetic powder includes at leastone element which is selected from the group comprising Cu, Si, Ga, Ti,V, Ta, Zr, Nb, Mo, Hf, Ag, Zn, P, Ge and Cr.

Furthermore, it is preferred that the content of the element is equal toor less than 3 at %.

Moreover, it is preferred that the magnetic powder is constituted from acomposite structure having a soft magnetic phase and a hard magneticphase.

Moreover, it is also preferred that the isotropic bonded magnet is to besubjected to multipolar magnetization or is already subjected tomultipolar magnetization. In this case, it is also preferred that theisotropic bonded magnet is used for a motor.

These and other objects, structures and advantages of the presentinvention will be apparent from the following detailed description ofthe invention and the examples taken in conjunction with the appendeddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration which schematically shows one example of acomposite structure (nanocomposite structure) of magnetic powderaccording to the present invention.

FIG. 2 is an illustration which schematically shows one example of acomposite structure (nanocomposite structure) of magnetic powderaccording to the present invention.

FIG. 3 is an illustration which schematically shows one example of acomposite structure (nanocomposite structure) of magnetic powderaccording to the present invention.

FIG. 4 is a perspective view showing an example of the configuration ofan apparatus (quenched ribbon manufacturing apparatus) for manufacturinga magnet material.

FIG. 5 is a sectional side view showing the situation in the vicinity ofcolliding section of the molten metal with a cooling roll in theapparatus shown in FIG. 4.

FIG. 6 is a J-H diagram (coordinate) for explaining the irreversiblesusceptibility.

FIG. 7 is a J-H diagram (coordinate) that represents demagnetizationcurves and recoil curves.

FIG. 8 is a table showing the evaluation of a first example of thepresent invention.

FIG. 9 is a table showing the evaluation of a second example of thepresent invention.

FIG. 10 is a table showing the evaluation of a third example of thepresent invention.

FIG. 11 is a table showing the evaluation of a fourth example of thepresent invention.

DETAILED DESCRIPTION OF THE INVENTION

In the following, magnetic powder according to this invention andisotropic rare-earth bonded magnets formed from the magnetic powderswill be described in detail.

At present, a magnet having high magnetic flux density is practicallyrequired in order to reduce the size of motors or other electricaldevices. In a bonded magnet, factors that determine the magnetic fluxdensity are the magnetic performance (magnetization, in particular) ofmagnetic powder and the content (compositional ratio) of the magneticpowder contained in the bonded magnet. When the magnetic performance(magnetization) of the magnetic powder itself is not so high, a desiredmagnetic flux density cannot be obtained unless the content of themagnetic powder in the bonded magnet is increased to an extremely highlevel.

As mentioned in the above, MQP-B powder made by MQI Corp. which is nowbeing widely used can not provide sufficient magnetic flux densitydepending on its use. As a result, in manufacturing the bonded magnets,it is required to increase the content of the magnetic powder in thebonded magnet, that is, it is required to increase the magnetic fluxdensity. However, this in turn leads to the lack of reliability in thecorrosion resistance property, heat resisting property and mechanicalstrength thereof and the like. Further, there is a problem in that theobtained magnet has a poor magnetizability due to its high coercivity.

In contrast, the magnetic powder and the isotropic bonded magnet(isotropic rear-earth bonded magnet) according to this invention canobtain a sufficient magnetic flux density and an adequate coerciveforce. As a result, without extremely increasing the content of themagnetic powder in the bonded magnet, it is possible to provide a bondedmagnet having a high strength and having excellent moldability,corrosion resistance property and magnetizability. This makes itpossible to reduce the size of the bonded magnet and increase itsperformance, thereby contributing to reduce the size of motors and otherdevices employing magnets.

Further, the magnetic powder of the present invention may be formed soas to constitute a composite structure having a hard magnetic phase anda soft magnetic phase.

While the MQP-B powder made by MQI Corp. is a single phase structure ofa hard magnetic phase, the magnetic powder of the present invention is ananocomposite structure which also has a soft magnetic phase having ahigh magnetization. Accordingly, it has an advantage that the totalmagnetization of the system as a whole is high. Further, the recoilpermeability of the bonded magnet becomes high, there is an advantagethat, even after a reverse magnetic field is applied, the demagnetizingfactor remains small.

The magnetic powder according to this invention has alloy compositionsrepresented by R_(x)(Fe_(1−y)Co_(y))_(100-x-z-w)B_(z)Al_(w) (R is atleast one kind of rare-earth elements, x is 8.1-9.4 at %, y is 0-0.30, zis 4.6-6.8 at %, and w is 0.02-1.5 at %).

Examples of rare-earth metals R include Y, La, Ce, Pr, Nd, Pm, Sm, Eu,Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, and a misch metal. In this connection, Rmay include one kind or two or more kinds of these elements.

The content of R is set at 8.1-9.4 at %. When the content of R is lessthan 8.1 at %, sufficient coercive force cannot be obtained, andaddition of Al enhances the coercive force only to a small extent. Onthe other hand, when the content of R exceeds 9.4 at %, sufficientmagnetic flux density fails to be obtained because of the drop in themagnetization potential.

Here, it is preferable that R includes the rare-earth elements Nd and/orPr as the principal ingredient. The reason for this is that theserare-earth elements enhance the saturation magnetization of the hardmagnetic phase which constitutes the composite structure (especially,nanocomposite structure) the magnetic powder, and are effective inrealizing satisfactory coercive force as a magnet.

Moreover, it is preferable that R includes Pr, and its ratio to thetotality of R is 5-75%, and more preferably 10-60%. This is because whenthe ratio lies in this range, it is possible to improve the coercivityand the rectangularity by hardly causing a drop in the remanent magneticflux density.

Furthermore, it is preferable that R includes Dy and its ratio to thetotality of R is equal to or less than 14%. When the ratio lies in thisrange, the coercivity can be improved without causing marked drop in theremanent magnetic flux density, and the heat resisting property is alsoimproved.

Cobalt (Co) is a transition metal element having properties similar toFe. By adding Co, that is by substituting a part of Fe by Co, the Curietemperature is elevated and the temperature characteristic of the powderis improved. However, if the substitution ratio of Fe by Co exceeds0.30, both of the coercive force and the magnetic flux density tend tofall off. The range of 0.05-0.20 of the substitution ratio of Fe by Cois more preferable since in this range not only the temperaturecharacteristic (heat resisting property and heat stability) of themagnetic powder but also the magnetic flux density thereof are improved.In this regard, it is to be noted that a part of Fe or Co may besubstituted by Ni.

Boron (B) is an element which is important for obtaining high magneticcharacteristics, and its content is set at 4.6-6.8 at %. When thecontent of B is less than 4.6 at %, the rectangularity of the magneticpower is deteriorated. On the other hand, when the content of B exceeds6.8 at %, the nonmagnetic phase increase and the magnetic flux densitydrops sharply.

Aluminum (Al) is an element which is advantageous for improving thecoercive force, and the effect of improvement of the coercive force isconspicuous when its content lies in the range of 0.02-1.5 at %. Inaddition, the rectangularity and the maximum magnetic energy product areimproved in this range in accompanying with the improvement in thecoercive force, and the corrosion resistance property becomes alsosatisfactory. In this connection, however, when the content of R is lessthan 8.1 at %, these effects due to addition of Al are very small asmentioned above. Further, when the content of Al exceeds 1.5 at %, thedrop in the magnetization is conspicuous, which makes it difficult toobtain a high magnetic density flux, thereby lowering the coerciveforce.

Further, another important effect obtained by containing 0.02-1.5 at %of Al is that the irreversible susceptibility (X_(irr)) describedhereinafter can be made small and the irreversible flux loss can beimproved so that the heat resisting property (heat stability) of themagnet is improved. In this connection, it is to be noted that if theamount of Al is less than 0.02 at %, such effect is hardly realized andthe effect for improving coercive force described above is small.

Of course, Al itself is a known substance. However, in the presentinvention, it has found through repeatedly conducted experiments andresearches that by containing 0.02-1.5 at % of Al to the magnetic powderconstituted from a composite structure having a soft magnetic phase anda hard magnetic phase, the following four effects are realized, inparticular these four effects are realized at the same time, and this isthe significance of the present invention.

(1) The coercive force of the magnetic powder can be improved whilemaintaining excellent rectangularity and the maximum magnetic energyproduct.

(2) The irreversible susceptibility (X_(irr)) described below can bemade small.

(3) The irreversible flux loss can be improved, that is the absolutevalue thereof can be lowered.

(4) Better corrosion resistance property can be maintained.

As described in the above, the feature of this invention can be found inthe incorporation of a minute amount or trace amount of Al, and additionof Al in the amount exceeding 1.5 at % gives rather an inverse effectand therefore it is not the intent of this invention.

In this connection, the preferred range of the content of Al is 0.02-1.5at % as described above. In this case, it is more preferable that theupper limit of the range is 1.2 at % and it is the most preferable thatthe upper limit is 0.8 at %.

In addition, for the purpose of further improving the magneticcharacteristics, at least one other element selected from the groupcomprising Cu, Si, Ga, Ti, V, Ta, Zr, Nb, Mo, Hf, Ag, Zn, P, Ge and Cr(hereinafter, referred to as “Q”) may be contained as needed. Whencontaining the element belonging to Q, it is preferable that the contentthereof should be less than 3 at %, and it is more preferable that thecontent thereof lies in the range of 0.2-3 at %, and it is the mostpreferable that the content thereof lies in the range of 0.5-2 at %.

The addition of the element belonging to Q makes it possible to exhibitinherent effect of the kind of the element. For example, the addition ofCu, Si, Ga, V, Ta, Zr, Cr or Nb exhibits an effect of improvingcorrosion resistance property. Among these elements, the addition of Siexhibits the effects (1) to (3) described above in addition to theeffect of improving the corrosion resistance property.

As described above, the magnetic material of the present invention has acomposite structure having a soft magnetic phase and a hard magneticphase.

In this composite structure (nanocomposite structure), a soft magneticphase 10 and a hard magnetic phase 11 exist in a pattern (model) asshown in, for example, FIG. 1, FIG. 2 or FIG. 3, where the thickness orgrain diameter of the respective phases is on the order of nanometers(for example, 1-100 nm). Further, the soft magnetic phase 10 and thehard magnetic phase 11 are arranged adjacent to each other (this alsoincludes the case where these phases are adjacent through grain boundaryphase), which makes it possible to perform magnetic exchange interactiontherebetween.

In this case, the average grain diameter size is preferably 5 to 50 nmand more preferably 10 to 40 nm. In the case where the average crystalgrain size (diameter) is less than the lower limit value, the influenceof the magnetic exchange interaction becomes too strong and therebymagnetic inversion is likely to occur, which may result in the casewhere the coercive force is deteriorated.

On the other hand, when the average crystalline grain size exceeds theupper limit value, the crystalline grain size becomes large while theinfluence of the magnetic exchange interaction between crystallinegrains is weakened, thus leading to the case that the magnetic fluxdensity, coercive force and rectangularity and maximum energy productmay be deteriorated.

The patterns illustrated in FIG. 1 to FIG. 3 are only specific examples,and are not limited thereto. For example, the soft magnetic phase 10 andthe hard magnetic phase 11 in FIG. 2 are interchanged.

The magnetization of the soft magnetic phase readily changes itsorientation by the action of an external magnetic field. Therefore, whenit coexists with the hard magnetic phase, the magnetization curve forthe entire system shows a stepped “serpentine curve” in the secondquadrant of the J-H diagram. However, when the soft magnetic phase has asufficiently small size of less than several tens of nm, magnetizationof the soft magnetic body is sufficiently strongly constrained throughthe coupling with the magnetization of the surrounding hard magneticbody, so that the entire system exhibits functions like a hard magneticbody.

A magnet having such a composite structure (nanocomposite structure) hasmainly the following five features.

(1) In the second quadrant of the J-H diagram (that is, coordinate wherethe longitudinal axis represents magnetization (J) and the horizontalaxis represents magnetic field (H)), the magnetization springs backreversively (in this sense, such a magnet is also referred to as a“spring magnet”).

(2) It has a satisfactory magnetizability, and it can be magnetized witha relatively low magnetic field.

(3) The temperature dependence of the magnetic characteristics are smallas compared with the case where the system is constituted from a hardmagnetic phase alone.

(4) The changes in the magnetic characteristics with the lapse of timeare small.

(5) No deterioration in the magnetic characteristics is observable evenif it is finely pulverized.

In, the alloy composition described in the above, the hard magneticphase and the soft magnetic phase are composed of, for example,respectively by the following.

The hard magnetic phase: R₂TM₁₄B system (where, TM is Fe or Fe and Co),or R₂TM₁₄BAl system (or R₂TM₁₄BQ system, or R₂TM₁₄BalQ system).

The soft magnetic phase: TM (α-Fe or α-(Fe, Co) in particular), or analloy of TM and Al (or an alloy of TM and Q or an alloy of TM, Al andQ).

As for the magnetic powders according to this invention, it ispreferable that they are manufactured by quenching a molten alloy, andmore preferable that they are manufactured by pulverizing a quenchedribbon obtained by quenching and solidifying the molten metal of thealloy. An example of such a method will be described in the following.

FIG. 4 is a perspective view showing an example of the configuration ofan apparatus (quenched ribbon manufacturing apparatus) for manufacturinga magnet material by the quenching method using a single roll, and FIG.5 is a sectional side view showing the situation in the vicinity ofcolliding section of the molten metal with a cooling roll in theapparatus shown in FIG. 4.

As shown in FIG. 4, a quenched ribbon manufacturing apparatus 1 isprovided with a cylindrical body 2 capable of storing the magnetmaterial, and a cooling roll 5 which rotates in the direction of anarrow 9A in the figure relative to the cylindrical body 2. A nozzle(orifice) 3 which injects the molten metal of the magnet material alloyis formed at the lower end of the cylindrical body 2.

In addition, a heating coil 4 is arranged on the outer periphery of thecylindrical body 2 in the vicinity of the nozzle 3, and the magnetmaterial in the cylindrical body 2 is melted by inductively heating theinterior of the cylindrical body 2 through application of, for example,a high frequency wave to the coil 4.

The cooling roll 5 is constructed from a base part 51 and a surfacelayer 52 which forms a circumferential surface 53 of the cooling roll 5.

The base part 51 may be formed either integrally with the surface layer52 using the same material, or formed using a material different fromthat of the surface layer 52.

Although there is no particular limitation on the material of the basepart 51, it is preferable that it is a metallic material with high heatconductivity such as copper or a copper alloy in order to be able todissipate heat of the surface layer 52 as quickly as possible.

Further, it is preferable that the surface layer 52 is constituted of amaterial with heat conductivity equal to or lower than that of the basepart 51.

The quenched ribbon manufacturing apparatus 1 is installed in a chamber(not shown), and is operated preferably under the condition where theinterior of the chamber is filled with an inert or other kind of gas. Inparticular, in order to prevent oxidation of a quenched ribbon 8, it ispreferable that the gas is an inert gas such as argon, helium, nitrogenor the like.

In the quenched ribbon manufacturing apparatus 1, the magnet material(alloy) is placed in the cylindrical body 2 and melted by heating withthe coil 4, and the molten metal 6 is discharged from the nozzle 3.Then, as shown in FIG. 5, the molten metal 6 collides with thecircumferential surface 53 of the cooling roll 5, and after theformation of a puddle 7, the molten metal 6 is cooled down rapidly to besolidified while dragged.along the circumferential surface 53 of therotating cooling roll 5, thereby forming the quenched ribbon 8continuously or intermittently. Roll surface 81 of the quenched ribbon 8thus formed is soon released from the circumferential surface 53, andproceeds in the direction of an arrow 9B in FIG. 4. The solidificationinterface 71 of the molten metal is indicated by a broken line in FIG.5.

The optimum range of the circumferential velocity of the cooling roll 5depends upon the composition of the molten alloy, the wettability of thecircumferential surface 53 with respect to the molten metal 6, and thelike. However, for the enhancement of the magnetic characteristics, avelocity in the range of 1 to 60 m/s is normally preferable, and 5 to 40m/s is more preferable. If the circumferential velocity of the coolingroll 5 is too small, the thickness t of the quenched ribbon 8 is toolarge depending upon the volume flow rate (volume of the molten metaldischarged per unit time), and the diameter of the crystalline grainstends to increase. On the contrary, if the circumferential velocity istoo large, amorphous structure becomes dominant. Further, enhancement ofthe magnetic characteristics can be expected in neither case even if aheat treatment is given in the later stage.

Thus obtained quenched ribbon 8 may be subjected to a heat treatment forthe purpose of, for example, acceleration of recrystallization of theamorphous structure and homogenization of the structure. The conditionsof this heat treatment may be, for example, a heating in the range of400 to 900° C. for 0.5 to 300 min.

Moreover, in order to prevent oxidation, this heat treatment ispreferable to be performed in a vacuum or under a reduced pressure (forexample, in the range of 1×10⁻¹ to 1×10⁻⁶ Torr), or in a nonoxidizingatmosphere of an inert gas such as nitrogen, argon, helium or the like.

The quenched ribbon (thin ribbon-like magnet material) 8 obtained as inthe above has a microcrystalline structure or a structure in whichmicrocrystals are included in an amorphous structure, and exhibitsexcellent magnetic characteristics. The magnetic powder of thisinvention is obtained by pulverizing the quenched ribbon 8.

The pulverizing method of the quenched ribbon is not particularlylimited, and various kinds of pulverizing or crushing apparatus such asball mill, vibration mill, jet mill, and pin mill may be employed. Inthis case, in order to prevent oxidation, pulverization may be performedunder vacuum or reduced pressure (for example, under a low pressure of1×10⁻¹ to 1×10⁻⁶ Torr), or in a nonoxidizing atmosphere of an inert gassuch as nitrogen, argon, helium, or the like.

The average grain size of the magnetic powder is not particularlylimited. However, for magnetic powder to be used for manufacturingisotropic bonded magnets described later, by considering prevention ofoxidation of the magnetic powder and of deterioration in the magneticcharacteristics due to pulverization, it is preferable to choose therange of 0.5 to 150 μm, more preferably the range of 1.0 to 65 μm, andstill more preferably the range of 5 to 55 μm.

In order to obtain a better mold ability of the bonded magnet, it ispreferable to give a certain degree of dispersion to the grain sizedistribution of the magnetic powder. By so doing, it is possible toreduce the porosity of the bonded magnet obtained. As a result, it ispossible to raise the density and the mechanical strength of the bondedmagnet assuming the same content of the magnetic powder in the bondedmagnet, thereby enabling to further improve the magneticcharacteristics.

The obtained magnetic powder may be subjected to a heat treatment forthe purpose of, for example, removing the influence of stress introducedby the pulverization and controlling the crystalline grain size. Theconditions of the heat treatment are, for example, heating at atemperature in the range of 350 to 850° C. for 0.5 to 300 min.

In order to prevent oxidation of the powder, it is preferable to performthe heat treatment in a vacuum or under a reduced pressure (for example,in the range of 1×10⁻¹ to 1×10⁻⁶ Torr), or in a nonoxidizing atmosphereof an inert gas such as nitrogen, argon, and helium.

When a bonded magnet is manufactured using the magnetic powder describedin the above, the obtained magnetic powder has a satisfactorybindability with the binding resin (wettability of the binding resin),so that the bonded magnet has a high mechanical strength and excellentthermal stability (heat resisting property) and corrosion resistanceproperty. Consequently, it can be concluded that the magnetic powder issuitable for the manufacture of the bonded magnet.

In the above, the quenching method is described in terms of the singleroll method, but the twin roll method may also be employed. Besides,other methods such as the atomizing method which uses gas atomization,the rotating disk method, the melt extraction method, and the mechanicalalloying method (MA) may also be employed. Since such a quenching methodcan refine the metallic structure (crystalline grains), it is effectivefor enhancing the magnet characteristics, especially the coercivity orthe like, of the bonded magnet.

Next, the isotropic rare-earth bonded magnets (hereinafter, referred tosimply also as “bonded magnets”) according to this invention will bedescribed.

The bonded magnets of this invention is formed by binding the abovedescribed magnetic powder using a binding resin.

As for the binder, either of a thermoplastic resin or a thermosettingresin may be employed.

As the thermoplastic resin, for example, a polyamid (example: nylon 6,nylon 46, nylon 66, nylon 610, nylon 612, nylon 11, nylon 12, nylon6-12, nylon 6-66, nylon 6T and nylon 9T); a thermoplastic polyimide; aliquid crystal polymer such as an aromatic polyester; a polyphenyleneoxide; a polyphenylene sulfide; a polyolefin such as a polyethylene, apolypropylene and an ethylene-vinyl acetate copolymer; a modifiedpolyolefin; a polycarbonate; a poly methyl methacrylate; a polyestersuch as a poly ethylen terephthalate and a poly butylene terephthalate;a polyether; a polyether ether ketone; a polyetherimide; a polyacetal,or t he like; and a copolymer, a blended body, and a polymer alloyhaving these as main ingredients, or the like, may be mentioned, whereone kind or a mixture of two or more kinds of these may be employed.

Among these resins, a resin containing a polyamide as its mainingredient is particularly preferred from the viewpoint of especiallyexcellent moldability and high mechanical strength. Further, a resincontaining a liquid crystal polymer and/or a poly phenylene sulfide asits main ingredient is also preferred from the viewpoint of enhancingthe heat resisting property. These thermoplastic resins also have anexcellent kneadability with the magnetic powder.

These thermoplastic resins provide an advantage in that a wide range ofselection can be made. For example, it is possible to provide athermoplastic resin having a good moldability or to provide athermoplastic resin having good heat resisting property and mechanicalstrength by appropriately selecting their kinds, copolymerization or thelike.

On the other hand, as the thermosetting resin, various kinds of epoxyresins of bisphenol type, novolak type, and naphthalene-based, aphenolic resin, a urea resin, a melamine resin, a polyester (or anunsaturated polyester) resin, a polyimide resin, a silicone resin, apolyurethane resin, or the like, for example, may be mentioned, and onekind or a mixture of two or more kinds of these may be employed.

Among these resins, an epoxy resin, a phenolic resin, a polyimide resin,or a silicone resin is preferable from the viewpoint of their specialexcellence in the moldability, high mechanical strength, and high heatresisting property, and an epoxy resin is especially preferable. Thesethermosetting resins also have an excellent kneadability with themagnetic powder and homogeneity in kneading.

The unhardened thermosetting resin to be used may be either in liquidstate or in solid (powdery) state at room temperature.

A bonded magnet according to this invention described in the above maybe manufactured, for example, as in the following. First, a bondedmagnet composite (compound) which contains the magnetic powder, a binderresin, and an additive (antioxidant, lubricant, or the like) as needed,is prepared. Then, the prepared compound is formed into a desired magnetform in a space free from magnetic field by a molding method such ascompression molding (press molding), extrusion molding, or injectionmolding. When the binding resin used is a thermosetting type, theobtained green compact is hardened by heating or the like after molding.

In the three kinds of molding method, the extrusion molding and theinjection molding (in particular, the injection molding) have advantagesin that the latitude of shape selection is broad, the productivity ishigh, and the like. However, these molding methods require to ensure asufficiently high fluidity of the compound in the molding machine inorder to obtain satisfactory moldability. For this reason, in thesemethods it is not possible to increase the content of the magneticpowder, namely, to make the bonded magnet having high density, ascompared with the case of the compression molding method. In thisinvention, however, it is possible to obtain a high magnetic fluxdensity as will be described later, so that excellent magneticcharacteristics can be obtained even without making the bonded magnethigh density. This advantage of the present invention can also beextended even in the case where bonded magnets are manufactured by theextrusion molding method or the injection molding method.

The content of the magnetic powder in the bonded magnet is notparticularly limited, and it is normally determined by considering thecompatibility of the molding method and moldability, and high magneticcharacteristics. More specifically, it is preferable to be in the rangeof 75-99 wt %, and more preferably in the range of 85-97.5 wt %.

In particular, for a bonded magnet to be manufactured by the compressionmolding method, the content of the magnetic powder is preferable to bein the range of 90-99 wt %, and more preferably in the range of 93-98.5wt %.

For a bonded magnet to be manufactured by the extrusion molding or theinjection molding, the content of the magnetic powder is preferable tobe in the range of 75-98 wt %, and more preferably in the range of 85-97wt %.

The density ρ of the bonded magnet is determined by factors such as thespecific gravity of the magnetic powder contained in the magnet and thecontent of the magnetic powder, and porosity of the bonded magnet andthe like. In the bonded magnets according to this invention, the densityρ is not particularly limited, but it is preferable to be in the rangeof 5.3-6.6 g/cm³, and more preferably in the range of 5.5-6.4 g/cm³.

In this invention, since the magnetic flux density and the coerciveforce of the magnetic powder are high and the magnetic powder has arelatively larger coercive force, the molded bonded magnet providesexcellent magnetic characteristics (especially, high maximum magneticenergy product) even when the content of the magnetic powder isrelatively low. In this regard, it goes without saying that it ispossible to obtain the excellent magnetic characteristics in the casewhere the content of the magnetic powder is high.

The shape, dimensions, and the like of the bonded magnet manufacturedaccording to this invention are not particularly limited. For example,as to the shape, all shapes such as columnar, prism-like, cylindrical(ring-shaped), circular, plate-like, curved plate-like, and the like areacceptable. As to the dimensions, all sizes starting from large-sizedone to ultraminuaturized one are acceptable. However, as repeatedlydescribed in this specification, the present invention is particularlyadvantageous in miniaturization and ultraminiaturization of the bondedmagnet.

The bonded magnet of this invention as described in the above hasmagnetic characteristics in which the irreversible susceptibility(X_(irr)) which is measured by using an intersectioning point of ademagnetization curve in the J-H diagram (that is, coordinate where thelongitudinal axis represents magnetization (J) and the horizontal axisrepresents magnetic field (H)) representing the magnetic characteristicsat the room temperature and a straight line which passes the origin inthe J-H diagram and has a gradient (J/H) of −3.8×10−⁶ H/m as a startingpoint is less than 5.0×10−⁷ H/m, and the intrinsic coercive force(H_(CJ)) of the magnet at the room temperature is in the range of406-717 kA/m. Hereinafter, explanation will be made with regard to theirreversible susceptibility (X_(irr)) and the intrinsic coercive force(H_(CJ)).

As shown in FIG. 6, the irreversible susceptibility (X_(irr)) is theparameter which is represented by the following formula (unit isHenry/m, which is represented by H/m in this specification), wherein agradient of a tangential line of the demagnetization curve at a certainpoint P on the demagnetization curve in the J-H diagram is defined bydifferential susceptibility (X_(dif)) and a gradient of a recoil curvewhen the recoil curve from the point P is drawn with the demagnetizationfield being once reduced (that is, a gradient connecting the both endsof the recoil curve) is defined by reversible susceptibility (X_(rev)).

Irreversible Susceptibility (X_(irr))=differential susceptibility(X_(dif))−reversible susceptibility(X_(rev))

In this connection, it is to be noted that in the present invention, thepoint P is defined as an intersectioning point of the demagnetizationcurve and the straight line y which passes the origin in the J-H diagramand has a gradient (J/H) of −3.8×10−⁶ H/m.

The reason why the upper limit value of the irreversible susceptibility(X_(irr)) at the room temperature is defined as 5.0×10−⁷ H/m is asfollows.

As stated in the above, the irreversible susceptibility (X_(irr))represents the changing ratio of the magnetization, which is notreturned even if the absolute value thereof is reduced once afterdemagnetization is applied, with respect to the magnetic field.Accordingly, by restraining the irreversible susceptibility (X_(irr)) toa relatively small value, it is possible to improve heat stability ofthe bonded magnet and especially to reduce the absolute value of theirreversible flux loss. Actually, within the range of the irreversiblesusceptibility (X_(irr)) of the present invention, the irreversible fluxloss obtained when the bonded magnet is being left in the atmosphere of100° C. for one hour and then the temperature is lowered into roomtemperature is equal to or less than 5% in its absolute value, whichmeans that practically satisfactory heat resisting property (inparticular when used in motors or the like), that is heat stability canbe obtained.

In contrast, when the irreversible susceptibility (X_(irr)) exceeds5.0×10−⁷ H/m, the absolute value of the irreversible flux loss isincreased, so that it is not possible to obtain satisfactory heatstability. Further, since the intrinsic coercive force (H_(CJ)) islowered and the rectangularity thereof becomes poor, use of the obtainedbonded magnet is limited to the case where the permeance coefficient(Pc) becomes large (e.g. Pc≧5). Furthermore, the lowered coercive forcereduces the heat stability.

The reason why the irreversible susceptibility (X_(irr)) at the roomtemperature is defined as 5.0×10−⁷ H/m is described above. However, itis preferred that the value of the irreversible susceptibility (X_(irr))is as smaller as possible. Therefore, in the present invention, it ispreferable that the irreversible susceptibility (X_(irr)) is equal to orless than 4.5×10−⁷ H/m, and it is more preferable that the irreversiblesusceptibility (X_(irr)) is equal to or less than 4.0×10−⁷ H/m.

It is preferred that the intrinsic coercive force (H_(CJ)) of the bondedmagnet at room temperature is 406 to 717 kA/m, and 435 to 677 kA/m ismore preferable.

If the intrinsic coercive force (H_(CJ)) exceeds the above upper limitvalue, magnetizability is deteriorated. On the other hand, if theintrinsic coercive force (H_(CJ)) is lower than the lower limit value,demagnetization occurs conspicuously when a reverse magnetic field isapplied depending upon the usage of the motor and the heat resistingproperty at a high temperature is deteriorated. Therefore, by settingthe intrinsic coercive force (H_(CJ)) to the above range, in the casewhere the bonded magnet (cylindrical magnet in particular) is subjectedto multipolar magnetization, a satisfactory magnetization can beaccomplished even when a sufficiently high magnetizing field cannot besecured, which makes it possible to obtain a sufficient magnetic fluxdensity, and to provide a high performance bonded magnet, especially abonded magnet for motor.

The maximum magnetic energy product (BH)_(max) of the bonded magnet ofthe present invention is not particularly limited to the specific value.However, in the present invention, 87 to 125 kJ/m³ is preferable and 100to 125 kJ/m³is more preferable.

EXAMPLES Example 1

Magnetic powders with alloy compositionsNd_(8.7)Fe_(77.2−w)Co_(8.5)B_(5.6)Al_(w) (that is, various types ofmagnetic powders in which the content w of Al is changed variously) wereobtained by the method described below.

First, each of the materials Nd, Fe, Co, B, and Al was weighed to cast amother alloy ingot, and a sample of about 15 g was cut out from theingot.

A quenched ribbon manufacturing apparatus 1 as shown in FIG. 4 and FIG.5 was prepared, and the sample was placed in a quartz tube 2 having anozzle (circular orifice) 3 at the bottom. After evacuating the interiorof a chamber in which the quenched ribbon manufacturing apparatus 1 ishoused, an inert gas (Ar gas and helium gas) was introduced to obtain anatmosphere with desired temperature and pressure.

Then, the ingot sample in the quartz tube 2 was melted by high frequencyinduction heating, the circumferential velocity and the jetting pressure(difference between the inner pressure of the quartz tube 2 and thepressure of the atmosphere) were adjusted to 20 m/s and 40 kPa,respectively. Under the state, the molten metal was jetted against thecircumferential surface 53 of the cooling roll 5, to obtain a quenchedribbon (average thickness of about 30 μm, and average width of about 1.6mm).

The quenched ribbon was then coarsely crushed, and the powder wassubjected to a heat treatment in an argon atmosphere at 680° C. for 300sec. In this way, the various types of magnetic powders each havingdifferent contents w of Al were obtained.

To analyze the phase structure of the obtained magnetic powders, therespective magnetic powder was subjected to X-ray diffraction usingCu-Kα line at the diffraction angle of 20°-60°. From the thus obtaineddiffraction pattern, the presence of diffracted peaks of a hard magneticphase, Nd₂(Fe,Co)₁₄B₁ phase, and a soft magnetic phase, α-(Fe,Co) phase,were confirmed. Further, from the observation result using atransmission electron microscope (TEM), the formation of a nanocompositestructure was confirmed in each magnetic powder.

Next, in order to adjust the grain size of the respective magneticpowders, each magnetic powder was ground by a granulator in an argon gasatmosphere to obtain magnetic powder having average grain size of 60 μm.

A composite (compound) for bonded magnet was prepared by mixing therespective magnetic powder with an epoxy resin and a small amount ofhydrazine antioxidant and then kneading them.

Then, each of the thus obtained compounds was crushed to be granular.Then, the granular substance was weighed and filled into a die of apress machine, and a molded body was obtained by compression molding (inthe absence of a magnetic field) the sample at a pressure of 7 ton/cm².

After releasing from the die, the epoxy resin was cured by heating at atemperature of 150° C. (that is subjected to cure treatment) and acolumnar isotropic bonded magnet with diameter 10 mm φ and height 7 mmwas obtained. The content of the magnetic powder in the respectivebonded magnets was 97.0 wt % and the magnetic density of the respectivebonded magnets was about 6.21 Mg/m³.

After pulse magnetization is performed for the respective bonded magnetsunder the magnetic field strength of 3.2 MA/m, magnetic characteristics(remanent magnetic flux density Br, intrinsic coercive force (H_(CJ)),and maximum magnetic energy product (BH)_(max)) were measured using a DCrecording fluxmeter under the maximum applied magnetic field of 2.0MA/m. The temperature at the measurement was 23° C. (that is, roomtemperature).

As shown in FIG. 7, in the measured demagnetization curve of J-Hdiagram, a recoil curve having a starting point P at an intersectioningpoint P between the demagnetization curve and a straight line whichpasses an origin and has a gradient of −3.8×10−⁶ H/m was produced withthe magnetic field being once changed to zero and then being returnedthe original state, and then the gradient of the recoil curve (that is,the gradient of the straight line connecting the both ends of the recoilcurve) was obtained and then it was defined as the reversiblesusceptibility(X_(rev)). Further, the gradient of a tangential line ofthe demagnetization curve at the intersectioning point P was obtainedand then it was defined as the differential susceptibility (X_(dif)).The irreversible susceptibility (X_(irr)) was obtained by the formula ofX_(irr)=X_(dif)−X_(rev). The results of them are shown in FIG. 8 atTable 1 therefore.

Next, the heat resisting property (heat stability) of the respectivebonded magnets (each having the column shape having diameter of 10 mmand height of 7 mm) was examined. The heat resisting property wasobtained by measuring the irreversible flux loss (ratio of flux loss)obtained when the bonded magnet was being left in the atmosphere of 100°C. for one hour and then the temperature was lowered to the roomtemperature, and then it was evaluated. The results thereof are shown inthe attached Table 1. In this connection, it is to be noted that smallerabsolute value of the irreversible flux loss (ratio of flux loss) meansmore excellent heat resisting property (heat stability).

Next, in order to evaluate the magnetizability of the respective bondedmagnets (each having the column shape having diameter of 10 mm andheight of 7 mm), the magnetizability thereof was measured by changingthe magnetized magnetic field variously. In this connection, the ratioof magnetization was represented using the ratio with respect to theremanent magnetic flux under the magnetized magnetic filed of 4.8 MA/m,where the remanent magnetic flux is represented by 100%. The size of themagnetized magnetic filed of each of the bonded magnets when the ratioof magnetization is 90% was shown in the attached Table 1. In thisTable, smaller value means more excellent magnetizability.

As seen from the attached Table 1, the isotropic bonded magnets formedof the magnetic powders in which the content w of Al is 0.02 to 1.5 at %and the irreversible susceptibility (X_(irr)) is equal to or less than5.0×10−⁷ H/m exhibit excellent magnetic characteristics (remanentmagnetic flux density, intrinsic coercive force and maximum magneticenergy product) and have small absolute value of the irreversiblesusceptibility (X_(irr)), so that the heat resisting property of thesemagnets is high and the magnetizability thereof is excellent.

In contrast, the isotropic bonded magnets of the comparative exampleswhich were composed from magnetic powders containing no Al or containing2.0 at % of Al (more than the upper limit of the present invention) havepoor magnetic characteristics. Further, the absolute value of theirreversible flux loss is large and the heat stability is low.

As described above, according to the present invention, it is possibleto obtain bonded magnets having high performance and high reliability(especially, heat resisting property). In particular, thesecharacteristics are exhibited when the bonded magnets are used inmotors.

Example 2

Quenched ribbons of which alloy compositions were(Nd_(1−y)Pr_(y))_(8.8)Fe_(bal)Co_(7.5)B_(5.8)Al_(0.7) (that is, varioustypes of quenched ribbons in which the substitution amount y of Pr ischanged variously) were manufactured in the same manner as Example 1,and then the manufactured quenched ribbons were subjected to heattreatment in the argon gas atmosphere at a temperature of 680° C. for 10minutes. Using the same analyzing method as that used in Example 1, ithas been confirmed that the structure of each of the quenched ribbonsconstitutes a nanocomposite structure.

Next, in the same manner as Example 1, magnetic powders were obtainedfrom the respective quenched ribbons, and then cylindrical (ring-shaped)isotropic bonded magnets having outer diameter of 20 mm, inner diameterof 18 mm and height of 7 mm were manufactured. The content of themagnetic powder in each of the bonded magnets was about 96.8 wt %.Further, the density of each of the bonded magnets was about 6.18 Mg/m³.

For these magnetic powders, magnetic characteristics (remanent magneticflux density Br, intrinsic coercive force (H_(CJ)), and maximum magneticenergy product (BH)_(max)) and the irreversible susceptibility (X_(irr))were measured, and then they were evaluated. The results thereof areshown in the attached Table 2.

Further, these bonded magnets were respectively subjected to multi-polemagnetization of 12 poles, and using each bonded magnet as a magnet fora rotor, a DC brush-less motor was assembled. Then, each of the DCmotors was rotated at 4000 rpm to measure a back electromotive forcegenerated in the coil winding thereof. As a result, it has beenconfirmed that a sufficiently high voltage could be obtained in each ofthe motors and these motors have a high performance.

Next, bonded magnets same as those of Example 1 were manufacturedexcepting that the various types of the magnetic powder having thedifferent substitution ratio y of Pr described above are used.

The heat resisting property (heat stability) and the magnetizability ofeach of the thus manufactured bonded magnets was measured in the sameway as Example 1, and the measurement results thereof were evaluated.The results thereof are shown in FIG. 9 at Table 2 thereof.

As seen from the attached Table 2, each of the isotropic bonded magnetshas excellent magnetic characteristics (remanent magnetic flux densityBr, intrinsic coercive force (H_(CJ)), and maximum magnetic energyproduct (BH)_(max)) and the absolute value of the irreversible flux lossthereof is small, so that the heat resisting property (heat stability)is high and the magnetizability thereof is excellent. In particular, itis understood that the intrinsic coercive force and the maximum magneticenergy product (rectangularity) are improved while the excellent heatresisting property and magnetizability are maintained, by substituting apart of Nd with a predetermined amount of Pr (that is, an amount equalto or less than 75% with respect to the whole amount of R).

As stated in the above, according to the present invention, it ispossible to provide bonded magnets having high performance and highreliability (especially, heat resisting property). In particular, thesecharacteristics are exhibited when these bonded magnets are used inmotors.

Example 3

Quenched ribbons of which alloy compositions were((Nd_(0.5)Pr_(0.5)))_(z)Dy_(1−z))_(9.0)Fe_(bal)Co_(7.7)B_(5.6)Al_(0.5)(that is, various types of quenched ribbons in which the substitutionamount (1−z) of Dy is changed variously) were manufactured in the samemanner as Example 1, and then the manufactured quenched ribbons weresubjected to heat treatment in the argon gas atmosphere at a temperatureof 680° C. for 12 minutes. Using the same analyzing method as that usedin Example 1, it has been confirmed that the structure of each of thequenched ribbons constitutes a nanocomposite structure.

Next, in the same manner as Example 1, magnetic powders were obtainedfrom the respective quenched ribbons, and then cylindrical (ring-shaped)isotropic bonded magnets having outer diameter of 20 mm, inner diameterof 18 mm and height of 7 mm were manufactured. The content of themagnetic powder in each of the bonded magnets was about 96.8 wt %.Further, the density of each of the bonded magnets was about 6.20 Mg/m³.

For these magnetic powders, magnetic characteristics (remanent magneticflux density Br, intrinsic coercive force (H_(CJ)), and maximum magneticenergy product (BH)_(max)) and the irreversible susceptibility (X_(irr))were measured, and then they were evaluated. The results thereof areshown in FIG. 10 at Table 3 therefor.

Further, these bonded magnets were respectively subjected to multi-polemagnetization of 12 poles, and using each bonded magnet as a magnet fora rotor, a DC brush-less motor was assembled. Then, each of the DCmotors was rotated at 4000 rpm to measure a back electromotive forcegenerated in the coil winding thereof. As a result, it has beenconfirmed that a sufficiently high voltage can be obtained in each ofthe motors, and these motors have a high performance.

Next, bonded magnets same as those of Example 1 were manufacturedexcepting that the various types of the magnetic powder having thedifferent substitution ratio 1−z of Dy described above are used.

The heat resisting property (heat stability) and the magnetizability ofeach of the thus manufactured bonded magnets were measured in the sameway as Example 1, and the measurement results thereof were evaluated.The results thereof are shown in FIG. 10 at Table 3 therefor.

As seen from the attached Table 3, each of the isotropic bonded magnetshas excellent magnetic characteristics (remanent magnetic flux densityBr, intrinsic coercive force (H_(CJ)), and maximum magnetic energyproduct (BH)_(max)) and the absolute value of the irreversible flux lossthereof is small, so that the heat resisting property (heat stability)is high and the magnetizability thereof is excellent. In particular, itis understood that the intrinsic coercive force and the maximum magneticenergy product (rectangularity) were improved while the excellent heatresisting property and magnetizability are maintained, by adding apredetermined amount of Dy (equal to or less than 14% with respect tothe whole amount of R).

As stated in the above, according to the present invention, it ispossible to provide bonded magnets having high performance and highreliability (especially, heat resisting property). In particular, thesecharacteristics are exhibited when these bonded magnets are used inmotors.

Example 4

Quenched ribbons of which alloy compositions wereNd_(5.3)Pr_(2.8)Dy_(0.6)Fe_(76.8−v)Co_(8.5)B_(5.6)Al_(0.4)Si_(v) (thatis, various types of quenched ribbons in which the content v of Si ischange d variously) were manufactured in the same manner as Example 1,and then the manufactured quenched ribbons were subjected to heattreatment in the argon gas atmosphere at a temperature of 670° C. for 8minutes. Using the same analyzing method as that used in Example 1, ithas been confirmed that the structure of each of the quenched ribbonsconstitutes a nanocomposite structure.

Next, in the same manner as Example 1, magnetic powders were obtainedfrom the respective quenched ribbons, and then cylindrical (ring-shaped)isotropic bonded magnets having outer diameter of 20 mm, inner diameterof 18 mm and height of 7 mm were manufactured using the magneticpowders. The content of the magnetic powder in each of the bondedmagnets was about 96.9 wt %. Further, the density of each of the bondedmagnets was about 6.19 Mg/m³.

For these magnetic powders, magnetic characteristics (remanent magneticflux density Br, intrinsic coercive force (H_(CJ)), and maximum magneticenergy product (BH)_(max)) and the irreversible susceptibility (X_(irr))were measured, and then they were evaluated. The results thereof areshown in FIG. 11 at Table 4 therefor.

Further, these bonded magnets were respectively subjected to multi-polemagnetization of 12 poles, and using each bonded magnet as a magnet fora rotor, a DC brush-less motor was assembled. Then, each of the DCmotors was rotated at 4000 rpm to measure a back electromotive forcegenerated in the coil winding thereof. As a result, it has beenconfirmed that a sufficiently high voltage can be obtained in each ofthe motors, and these motors have a high performance.

Next, bonded magnets same as those of Example 1 were manufacturedexcepting that various types of the magnetic powder having the differentcontent v of Si are used.

The heat resisting property (heat stability) and the magnetizability ofeach of the bonded magnets were measured in the same way as Example 1.Further, using the method described below, the heat resisting property(heat stability) and the magetizability thereof were measured, andevaluated. The results thereof are shown in FIG. 11 at Table 4 therefor.

The corrosion resistance property of the respective bonded magnet wasevaluated by a dewing test (dew formation test). This rust examinationwas carried out by alternately placing each of the magnetic powders inthe atmosphere at a temperature of 30° C. and a RH of 50% for 15 minutesor in the atmosphere at a temperature of 80° C. and a RH of 95% RH forfifteen minutes, and this was repeated for 24 times. Thereafter, thesurface of each magnet was observed by a microscope and the degree ofthe generation of the rust was evaluated from the viewpoints of thefollowing four steps.

A: no rust was generated

B: a very small amount of rust was generated

C: rust was generated

D: rust was remarkably generated

The bonded magnets (ten bonded magnets for each) were immersed into abath containing water at a temperature of 60° C. and a RH of 95%, andthen the average time required until any rust is generated in each ofthe bonded magnets was examined. The results thereof were evaluated fromthe viewpoints of the following four steps.

A: no rust was generated after 500 hours was past

B: rust was generated between 400 hours and 500 hours

C: rust was generated between 300 hours and 400 hours

D: rust was generated within 300 hours

As seen from the attached Table 4, each of the isotropic bonded magnetsexhibits excellent magnetic characteristics (remanent magnetic fluxdensity, intrinsic coercive force and maximum magnetic energy product)and heat resisting property (heat stability), and the magnetizability ofthe respective magnets is good.

In particular, the bonded magnets composed from the magnetic powder inwhich a predetermined amount of Si (0.1 to 3 at %) is contained have animproved corrosion resistance property in the magnetic powder itself aswell as the bonded magnet formed therefrom as compared with the bondedmagnets containing no Si. Therefore, it is possible to omit or simplifycorrosion preventing treatment such as application of anti-corrosioncoating on the surfaces of the bonded magnets when they are actuallyused.

As described above, according to the present invention, it is possibleto provide bonded magnets having high performance and high reliability(especially, high heat resisting property and corrosion resistanceproperty). In particular, when these bonded magnets are used in motors,high performance can be exhibited.

Example 5

Isotropic bonded magnets were manufactured in the same manner as thatused in Examples 1-4 excepting that the bonded magnets were producedusing the extrusion molding. In this regard, it is to be noted thatpolyamide (Nylon 610) was used in the respective bonded magnets as abinder. Further, the content of the magnetic powder in the respectivebonded magnets was about 95.5 wt % and the magnetic density thereof wasabout 5.85 Mg/m³.

For each of these bonded magnets, the above described measurement andevaluation were carried out (including the evaluation for corrosionresistance property). As a result, it has been confirmed that the sameresults as those of the Examples 1 to 4 were obtained. In particular,corrosion resistance property thereof was excellent.

Example 6

Isotropic bonded magnets of the present invention were manufactured inthe same manner as that used in Examples 1-4 excepting that the bondedmagnets were produced using the injection molding. In this regard, it isto be noted that poly phenylene sulfide was used in the respectivebonded magnets as a binder. Further, the content of the magnetic powderin the respective bonded magnets was about 94.1 wt % and the magneticdensity thereof was about 5.63 Mg/m³.

For each of these bonded magnets, the above described measurement andevaluation were carried out (including the evaluation for corrosionresistance). As a result, it has been confirmed that the same results asthose of the Examples 1 to 4 were obtained. In particular, corrosionresistance property thereof was excellent.

As described above, according to the present invention, the followingeffects can be obtained.

Since each of the magnetic powders has the composite structure having asoft magnetic phase and a hard magnetic phase and contains apredetermined amount of Al, they have high magnetizability and exhibitexcellent magnetic characteristics so that intrinsic coercive force andrectangularity thereof are especially improved.

The absolute value of the irreversible flux loss is small and excellentheat resisting property (heat stability) can be obtained.

Because of the high magnetic flux density that can be secured by thisinvention, it is possible to obtain a bonded magnet with high magneticperformance even if it is isotropic. In particular, since magneticperformance equivalent to or better than the conventional isotropicbonded magnet can be obtained with a magnet of smaller volume ascompared with the conventional isotropic bonded magnet, it is possibleto provide a high performance motor of a smaller size.

Moreover, since a higher magnetic flux density can be secured, inmanufacturing a bonded magnet sufficiently high magnetic performance isobtainable without pursuing any means for elevating the density of thebonded magnet. As a result, the dimensional accuracy, mechanicalstrength, corrosion resistance, heat resisting property (heat stability)and the like can be improved in addition to the improvement in themoldability, so that it is possible to readily manufacture a bondedmagnet with high reliability. In particular, when Si is containedtherein, further improved corrosion resistance can be obtained.

Since the magnetizability of the magnet according to this invention isexcellent, it is possible to magnetize a magnet with a lower magnetizingfield. In particular, multipolar magnetization or the like can beaccomplished easily and surely, and further a high magnetic flux densitycan be obtained.

Since a high density is not required to the bonded magnet, the presentinvention is adapted to the manufacturing method such as the extrusionmolding method or the injection molding method by which molding at highdensity is difficult as compared with the compression molding method,and the effects described in the above can also be realized in thebonded magnet manufactured by these molding methods. Accordingly,various molding method can be selectively used and thereby the degree ofselection of shaped for the bonded magnet can be expanded.

Finally, it is to be understood that the present invention is notlimited to Examples described above, and many changes or additions maybe made without departing from the scope of the invention which isdetermined by the following claims.

What is claimed is:
 1. A magnetic powder comprising: an alloycomposition represented by R_(x)(Fe_(1−y)Co_(y))_(100-x-z-w)B_(z)Al_(w)(where R is at least one rare-earth element, x is 8.1-9.4 at %, and y is0.0-0.30, z is 4.6-6.8 at %, and w is 0.02-1.5 at %), the magneticpowder being constituted from a composite structure having a softmagnetic phase and a hard magnetic phase; the soft magnetic phase andthe hard magnetic phase have a mean crystal grain size of 1-100 nm;wherein the magnetic powder has characteristics in which, when anisotropic bonded magnet is molded by mixing the magnet powder with abinding resin, the irreversible susceptibility (X_(irr)) which ismeasured by using an intersectioning point of a demagnetization curve inthe J-H diagram representing the magnetic characteristics at roomtemperature and a straight line which passes the origin in the J-Hdiagram and has a gradient (J/H) of −3.8−10⁻⁶ H/m as a starting point isless than 5.0×10⁻⁷ H/m, and the intrinsic coercive force (Hcj) of themagnet at room temperature is in the range of 406-717 kA/m.
 2. Themagnetic powder as claimed in claim 1, wherein the composite structureis a nanocomposite structure.
 3. The magnetic powder as claimed in claim1, wherein said R comprises rare-earth elements mainly containing Ndand/or Pr.
 4. The magnetic powder as claimed claim 1, wherein said Rincludes Pr and a ratio of Pr with respect to the total mass of said Ris 5-75%.
 5. The magnetic powder as claimed in claim 1, wherein said Rincludes Dy and a ratio of Dy with respect to the total mass of said Ris equal to or less than 14%.
 6. The magnetic powder as claimed in claim1, wherein the magnetic powder has been obtained by quenching the moltenstate alloy.
 7. The magnetic powder as claimed in claim 1, wherein themagnetic powder has been obtained by forming a quenched ribbon of thealloy a cooling roll and then pulverizing quenched ribbon.
 8. Themagnetic powder as claimed in claim 1, wherein the magnetic powder hasbeen subjected to a heat treatment at least once during themanufacturing process or after its manufacture.
 9. The magnetic powderas claimed in of claim 1, wherein the average grain size of the magneticpowder lies in the range of 0.5-150 μm.
 10. An isotropic rare-earthbonded magnet, which is formed by binding the magnetic powder as setforth in claim 1 with a binding resin.
 11. The magnetic powder of claim1 wherein the hard magnetic phase is the main phase.